Intelligent compressed air system and method

ABSTRACT

A system includes at least one sensor device in a compressed air line, at least one smart control valve in the compressed air line, and at least one processor to receive sensor data associated with the compressed air line from the at least one sensor device, store the sensor data, compare the sensor data from the at least one sensor device with a threshold to determine whether there is one of productive demand and non-productive demand from a demand source connected to the compressed air line, send a command to the at least one smart control valve based on the one of the productive demand and the non-productive demand from the demand source, and operate the at least one smart control valve based on the command to open the smart control valve when there is productive demand and close the smart control valve when there is non-productive demand.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Appl. No.62/729,465 filed Sep. 11, 2018, entitled “Apparatus and Method for theRemote Control of Flow Distribution and Fluid Condition Monitoring in aFluid Delivery System,” the entire contents of which is herebyincorporated herein by reference.

BACKGROUND

According to the Compressed Air & Gas Institute, there is over $3.2billion that is wasted each year because of inefficiencies associatedwith compressed air systems. Although popular, compressed air systemsare one of the least efficient power sources used in manufacturing.

It is known that leaks are a significant source of wasted energy in acompressed air system. Twenty to thirty percent of an air compressor'soutput may be wasted over the life of the air compressor. The leaks maycause problems including excessive financial costs, burdens associatedwith excess use, and a shorter life of air supply equipment due tooveruse. Current solutions may address leaks at a supply side of acompressed air system (e.g., compressors or air treatment) or mayaddress leaks at a demand side of the compressed air system (e.g.,nozzles, pneumatics).

It is with these issues in mind, among others, that various aspects ofthe disclosure were conceived.

SUMMARY

According to one aspect, an intelligent compressed air system provides asupply side system that may provide a supply of compressed air,compressed gas, or another fluid. The supply side system may be locatedat a facility and include one or more distribution components thatdistribute the compressed air such as one or more compressed air lines.Each of the one or more lines may provide a supply of compressed air toa demand source such as a machine or tool. The demand source may be aproductive demand when in use and may be a non-productive demand whennot in use. Each line may have one or more associated smart controlvalves that can open and close and one or more sensors that maydetermine flow and other information associated with the line. The smartcontrol valves and the sensor devices may communicate with a computingdevice using a communications network. As an example, the sensor devicemay determine that there is reduced demand at a demand source at aparticular time and send data to the computing device. The computingdevice may send a command to an associated smart control valve and thesmart control valve may close to reduce or stop flow of compressed airto the demand source. As another example, the computing device may senda command to the associated smart control valve at a particular time(e.g., 8 a.m.) when a plant is opening and an associated machine or toolis in use. The smart control valve may open to increase flow ofcompressed air to the demand source. As another example, the computingdevice may send a command to the associated smart control valve at aparticular time (e.g., 5 p.m.) when a plant is closing and an associatedmachine or tool is not in use. The smart control valve may close toreduce or stop flow of compressed air to the demand source. This mayreduce waste for the facility thereby saving use of resources andelectricity, and provide financial savings and benefits for thefacility.

According to an aspect, an intelligent compressed air system includes atleast one sensor device in a compressed air line, at least one smartcontrol valve in the compressed air line, and at least one processor toreceive sensor data associated with the compressed air line from the atleast one sensor device, store the sensor data in a computer-readablestorage medium, compare the sensor data from the at least one sensordevice with a threshold to determine whether there is one of productivedemand and non-productive demand from a demand source connected to thecompressed air line, send a command to the at least one smart controlvalve based on the one of the productive demand and the non-productivedemand from the demand source, and operate the at least one smartcontrol valve based on the command to open the smart control valve whenthere is productive demand and close the smart control valve when thereis non-productive demand.

According to another aspect, a method includes receiving, by at leastone processor, sensor data associated with a compressed air line from atleast one sensor device, storing, by the at least one processor, thesensor data in a computer-readable storage medium, comparing, by the atleast one processor, the sensor data from the at least one sensor devicewith a threshold to determine whether there is one of productive demandand non-productive demand from a demand source connected to thecompressed air line, sending, by the at least one processor, a commandto at least one smart control valve in the compressed air line based onthe one of the productive demand and the non-productive demand from thedemand source, and operating, by the at least one processor, the atleast one smart control valve based on the command to open the smartcontrol valve when there is productive demand and close the smartcontrol valve when there is non-productive demand.

According to an additional aspect, a non-transitory computer-readablestorage medium includes instructions stored thereon that, when executedby a computing device cause the computing device to perform operations,the operations including receiving sensor data associated with acompressed air line from at least one sensor device, storing the sensordata in the non-transitory computer-readable storage medium, comparingthe sensor data from the at least one sensor device with a threshold todetermine whether there is one of productive demand and non-productivedemand from a demand source connected to the compressed air line,sending a command to at least one smart control valve in the compressedair line based on the one of the productive demand and thenon-productive demand from the demand source, and operating the at leastone smart control valve based on the command to open the smart controlvalve when there is productive demand and close the smart control valvewhen there is non-productive demand.

These and other aspects, features, and benefits of the presentdisclosure will become apparent from the following detailed writtendescription of the preferred embodiments and aspects taken inconjunction with the following drawings, although variations andmodifications thereto may be effected without departing from the spiritand scope of the novel concepts of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate embodiments and/or aspects of thedisclosure and, together with the written description, serve to explainthe principles of the disclosure. Wherever possible, the same referencenumbers are used throughout the drawings to refer to the same or likeelements of an embodiment, and wherein:

FIG. 1 is a block diagram of an intelligent compressed air systemaccording to an example embodiment.

FIG. 2 illustrates a graph that shows a compressed air audit for afacility according to an example embodiment.

FIG. 3 illustrates a block diagram of a computing device of theintelligent compressed air system having an intelligent compressed airapplication according to an example embodiment.

FIG. 4 illustrates a flowchart of a process for operating theintelligent compressed air system according to an example embodiment.

FIG. 5 illustrates a usage graph associated with a plant that isdetermined by the intelligent compressed air system according to anexample embodiment.

FIG. 6 illustrates a graphical user interface of the intelligentcompressed air application according to an example embodiment.

FIG. 7 illustrates a block diagram of a computing device according to anexample embodiment.

DETAILED DESCRIPTION

Aspects of a method and system for providing intelligent and efficientusage of compressed air or gas includes a supply side system that mayprovide a supply of compressed air, gas, or another fluid. The supplyside system may be located at a facility and include one or moredistribution components that distribute the compressed air such as oneor more lines. Each of the one or more lines may provide a supply ofcompressed air to a demand source such as a machine or tool. The demandsource may be a productive demand when in use and may be anon-productive demand when not in use.

Each line may have one or more associated smart control valves that canopen and close and one or more sensors that may determine flow and otherinformation associated with the line. The smart control valves and thesensor devices may communicate with a computing device using acommunications network. As an example, the sensor device may send datato the computing device that indicates that there is reduced demand at ademand source at a particular time. Based on the data, the computingdevice may send a command to an associated smart control valve and thesmart control valve may close to reduce or stop flow of compressed airto the demand source.

In another example, the computing device may send a command to anassociated smart control valve based on a scheduled opening or closingof the valve at a particular time according to schedule data. As anexample, the smart control valve may be opened when an associated demandsource is in use (e.g., operating hours of a facility) and the smartcontrol valve may be closed when the demand source is not in use (e.g.,non-operating hours for the facility). This may reduce waste for thefacility thereby saving use of resources and electricity, and providefinancial savings and benefits for the facility.

Current solutions that address efficient usage of compressed air includelow flow air nozzles, high efficiency pneumatics, variable speed drivecompressors (VSD), compressor control systems, and high efficiency airdryers. However, these solutions are associated entirely on the demandside or on the supply side. There are significant overlooked savings andefficiencies that are associated with the compressed air distributionnetwork. By creating a smart and intelligent distribution network thatis connected to a communications network including one or more computingdevices, the system and method discussed herein can achieve betterresults and savings including energy savings and financial savings.

Increasing the efficiency of the compressed air distribution networkwill directly increase the lifetime of a supply side system. Bysupplying less air to the system, an associated compressor can run at alower average rate. As a result, the supply side system may have alonger lifetime. Over a ten year period, electricity may represent about75% of the financial cost of running a compressed air system. However,maintenance may be around 12% of the financial cost and equipment may beabout 12%. By increasing the efficiency, this may have a direct effecton the entire cost of running the system.

Based on previous studies, it has been determined that a total amount ofenergy to run an example compressed air system may be approximately$17,000 a year. A leak rate of the system was determined to be around28% of the average demand of the system. Such leaks are a significantsource of wasted energy in a compressed air system and typically wasteas much as 20-30% of an air compressor's output as in this example. Byeliminating or reducing the leak rate of the system, this may result in$5,000 in potential savings a year.

FIG. 1 shows a block diagram of an intelligent compressed air system 100according to an example embodiment. The intelligent compressed airsystem 100 may include a an intelligent compressed air apparatus 101that may include one or more smart control valves 102, one or moresensor devices 104, a communications network 106, and at least onecomputing device 108.

The intelligent compressed air apparatus 101 may be located between asupply side system 110 and one or more demand sources or fluid devicesat a facility. The one or more demand sources may be used at thefacility for up to twenty-four hours a day and may leak an amount offluid while idle. The supply side system 110 may be a source of a fluidsuch as a compressor.

The intelligent compressed air apparatus 101 may be added or combinedwith a pre-existing fluid delivery or compressed air system in afacility. The facility may be a factory or a plant such as amanufacturing plant and the one or more demand sources may be a machineor a tool that may use a consumable such as compressed air or anotherfluid. In one example, the facility may be a vehicle assembly plantwhere vehicles move down an assembly line having one or more machines ortools. The machine may be a robot, a metalworking machine tool such as astamping press, or a computer numerical control (CNC) machine that maybe used to process a material such as metal, plastic, wood, ceramic, oranother material. In another example, the facility may be an industrialfacility that molds widgets using one or more machines or tools. Thefacility may be any location where compressed air, gas, or fluid may beused such as a school building, an aircraft carrier, a cruise ship, or abattleship, among others.

The supply side system 110 may be a centrally available compressor thatpowers the one or more demand sources such as cylinders, air motors, andother pneumatic devices. The demand source may be a pneumatic devicethat makes use of the compressed air or fluid such as a handheld toolincluding a wrench, a screw driver, air nozzle for cleaning, or anindustrial machine such as a motor, a turbine, robotics, processcontrols, an entire assembly line, or another type of pneumatic device.

The one or more smart control valves 102 may control flow distributionin the intelligent compressed air system 100. The smart control valve102 may be an electronically controlled valve and have a relay to openor close the valve. The smart control valve 102 may be flow controlvalve such as a ball valve, a butterfly valve, a solenoid valve, oranother type of valve that may be located in a line of the facility. Theline may be used to distribute compressed air, compressed gas, oranother fluid from the supply side system 110 to one or more demandsources. The smart control valve may include a computing device that isconnected to a motor, an actuator, or a motorized system that mayoperate the smart control valve 102. In addition, the smart controlvalve 102 may have a power device that powers the smart control valve102. Each smart control valve 102 may be operated and controlledremotely. In other words, each smart control valve 102 may be operatedby a client computing device that is in communication with the computingdevice 108 via the communication network 106.

As a result, the smart control valves 102 may quickly and remotelyclose-off branches and lines in the intelligent compressed air system100 when they are not in use to reduce a number of active leak points inthe intelligent compressed air system 100 at the facility. By reducingthe number of potential leak points in the intelligent compressed airsystem 100, the facility can reduce an amount of fluid or compressed airand energy that is lost. The one or more smart control valves 102 mayoperate based on a schedule or systematic plan that may take intoaccount which demand points are active and working, which demand pointsare idle, shift changes at the facility, operating hours at thefacility, and cycle times, among other factors, in order to automate theone or more smart control valves and associated energy savings.

The facility may anticipate a standard leak rate of 20 or 30% of totaldemand. As an example, before operating hours at the facility, withoutthe smart control valves 102 or when the smart control valves 102 areopen, machines and tools that are connected to the lines may continuallyleak at the standard leak rate. However, during the hours of operation,the machines and tools may be used at a peak rate (e.g., 60% ofcapacity) and a higher amount of compressed air may be used. In otherwords, the leaks associated with demand points may continually bepresent. However, if a demand point is in use, the leak associated withthe demand point becomes part of the active demand.

At certain times such as off shifts, shift changes, lunches, or inbetween cycle times, the machines, robotics, and tools may not be used.The facility can take this usage into consideration to minimize the airlost through leaks by closing the one or more smart control valves 102that supply compressed air to the machines and tools when they are notin use. As an example, one robotic arm may perform a motion such asrotate a component and do this two seconds of every minute. Adding theone or more smart control valves 102 upstream can eliminate leaks forfifty-eight seconds of each minute when idle. Each worker or employeethat uses the machines and tools does not have to provide input to theintelligent compressed air system 100 and indicate when the machines andtools are in use. Rather, the intelligent compressed air system 100 maydetermine and predict when the machines and tools are in use based oncurrent real-time usage and other data such as the schedule data, plandata, machine learning, and other information.

As an example, the sensor device 104 may be a flow sensor and/or apressure sensor that may be located in or along a line of the facility.In another example, the sensor device 104 may be a temperature sensor, apressure sensor, and/or a humidity sensor. As an example, the sensordevice 104 may be a constant temperature anemometer (CTA). The sensordevice 104 may be in communication with the smart control valve 102 andalso may have a computing device that may send data and information tothe computing device 108. Although FIG. 1 shows that the sensor device104 is located closer to the demand source than the smart control valve102, they may be arranged in another order or in another way.

As an example, the sensor device 104 may be a constant temperatureanemometer (CTA) and utilize King's Law and the following equation todetermine flow velocity where U=Constant Temperature Anemometer (CTA)output, U₀=Free convection offset, k=Fluid constant, and v=Fluidvelocity.

U=U ₀*SQRT(1+k*v ^(n)), where n=0.2 . . . 0.5  Equation:

In one example, the k value and the n value may be determined fromexperimental results. While each sensor device 104 may have differentreadings, the sensor device 104 may generally be used to determine ifthe flow is in a leak profile or a demand profile. The differencebetween a leak state and a demand state in the flow is determinable bythe sensor device 104.

As an example, the sensor device 104 may be inserted into the flowstream in one of the lines of the intelligent compressed air system 100.The sensor device 104 may be inserted at a depth in the line such that acenter of the sensor device 104 and an associated probe sits at a centerof the flow. In another example, the sensor device 104 may be insertedat ⅔ of the center of the flow or in another location.

In one example, the computing device 108 may be housed in a housing andinstalled in a location in the facility near or along one or more of thedistribution components that distribute the compressed air such as theone or more lines of the facility. The computing device 108 may executean intelligent compressed air application that receives data andinformation from the one or more sensor devices 104. Based on the dataand information from the one or more sensor devices 104, the intelligentcompressed air application may operate the one or more smart controlvalves 102. The intelligent compressed air application may use a varietyof information to operate the one or more smart control valves 102.

The one or more smart control valves 102 may be operated using scheduledor systematic, remote or manual control. The intelligent compressed airapplication may use data including real-time information obtained fromthe one or more sensor devices 104 and other sources of information suchas schedule information for the facility (e.g., worker scheduleinformation for the facility), historical usage information for thefacility, historical usage information from other facilities, and otherinformation. As a result, the intelligent compressed air application mayreduce waste for the facility thereby saving use of resources andelectricity, and provide financial savings and benefits for thefacility.

The communication network 106 can be the Internet, an intranet, oranother wired or wireless communication network. For example, thecommunication network 106 may include a cellular network such as MobileCommunications (GSM) network, a code division multiple access (CDMA)network, 3^(rd) Generation Partnership Project (GPP) network, anInternet Protocol (IP) network, a wireless application protocol (WAP)network, a WiFi network, a Bluetooth network, a satellite communicationsnetwork, or an IEEE 802.11 standards network, as well as variouscommunications thereof. Other conventional and/or later developed wiredand wireless networks may also be used.

The smart control valve 102 includes at least one processor to processdata and memory to store data. The smart control valve 102 may include aSingle Board Computer (SBC) or a System on a Chip (SOC). Alternatively,the smart control valve 102 may include a Raspberry or Arduino® basedcomputing device. The processor processes communications, buildscommunications, retrieves data from memory, and stores data to memory.The processor and the memory are hardware. The memory may includevolatile and/or non-volatile memory, e.g., a computer-readable storagemedium such as a cache, random access memory (RAM), read only memory(ROM), flash memory, or other memory to store data and/orcomputer-readable executable instructions such as the intelligentcompressed air application. In addition, the smart control valve 102 mayinclude at least one communications interface to transmit and receivecommunications, messages, and/or signals.

The sensor device 104 includes at least one processor to process dataand memory to store data. In one example, the sensor device 104 mayinclude a Raspberry Pi® or Arduino® based computing device. Theprocessor processes communications, builds communications, retrievesdata from memory, and stores data to memory. The processor and thememory are hardware. The memory may include volatile and/or non-volatilememory, e.g., a computer-readable storage medium such as a cache, randomaccess memory (RAM), read only memory (ROM), flash memory, or othermemory to store data and/or computer-readable executable instructionssuch as the intelligent compressed air application. In addition, thesensor device 104 further includes at least one communications interfaceto transmit and receive communications, messages, and/or signals.

The at least one computing device 108 may be a server computing deviceand includes at least one processor to process data and memory to storedata. The at least one computing device 108 may include a cloud basedcomputing device. In one example, the computing device 108 may be aRaspberry Pi® or Arduino® based computing device. The processorprocesses communications, builds communications, retrieves data frommemory, and stores data to memory. The processor and the memory arehardware. The memory may include volatile and/or non-volatile memory,e.g., a computer-readable storage medium such as a cache, random accessmemory (RAM), read only memory (ROM), flash memory, or other memory tostore data and/or computer-readable executable instructions such as theintelligent compressed air application. In addition, the at least onecomputing device 108 further includes at least one communicationsinterface to transmit and receive communications, messages, and/orsignals.

The at least one computing device 108 may include a display and an inputdevice. The display is used to display visual components of theintelligent compressed air application, such as at a user interface. Inone example, the user interface may display a user interface of theintelligent compressed air application and a representation of therequested resources received from the computing device 108. The displaycan include a cathode-ray tube display, a liquid-crystal display, alight-emitting diode display, a touch screen display, and/or otherdisplays.

The input device is used to interact with the intelligent compressed airapplication or otherwise provide inputs to the computing device 108 andmay include a mouse, a keyboard, a trackpad, and/or the like. The inputdevice may be included within the display if the display is a touchscreen display. The input device allows a user of the computing device108 to manipulate the user interface of the intelligent compressed airapplication or otherwise provide inputs to the computing device 108.

As an example, FIG. 1 shows three different smart control valves 102 andthree different sensor devices 104. In this example, the supply sidesystem 110 has a header that connects via connection points to one ormore branches or lines. The supply side system 110 may deliver a fluidsuch as compressed air to one or more locations or destinationsincluding one or more machines or tools.

In FIG. 1 there are three branches, each for an individual point ofdemand, only two of which are productive. The third point of demand canbe viewed as leaks occurring at a machine or assembly line that is idleand currently not in use. As an example, FIG. 1 may show a factory or aportion of a factory during a shift, where the overall utilization rateis 66.7%. However, without the smart control valve 102, thenon-productive demand would receive compressed air from the supply sidesystem 110 and contribute to the overall energy demand. This would leadto a lower overall efficiency of the system 100 and an amount of wastedair released to the atmosphere.

The smart control valves 102 and the sensor devices 104 are arrangedbetween the supply side system 110 and one or more demand sources at afacility. A first demand source, such as a machine or tool, maycurrently have a non-productive demand 114. As shown in FIG. 1, thesensor device 104 receives data associated with the compressed airdistribution line. The data may be sent to the computing device 108 andindicate that there is non-productive demand. The computing device 108may compare the sensor data from the sensor device 104 with a thresholdto determine that there is non-productive demand 114 from the demandsource connected to the compressed air line. The computing device 108may send a command to the smart control valve 102 based on thenon-productive demand 114 from the demand source and operate the smartcontrol valve. In the example, the smart control valve 102 may closewhen there is non-productive demand 114. This is indicated in FIG. 1 bythe dashed line. FIG. 1 shows that there is one machine of the threeshown with non-productive demand 114.

Alternatively, the data may be sent to the computing device 108 thatindicates that there is productive demand 112 by the demand source suchas a machine or tool. The computing device 108 may compare the sensordata from the sensor device with a threshold to determine that there isproductive demand 112 from the demand source connected to the compressedair line. The computing device 108 may send a command to the smartcontrol valve 102 based on the productive demand 112 from the demandsource and operate the smart control valve 102. In the example, thesmart control valve 102 may open when there is productive demand 112.This is indicated in FIG. 1 by the solid line. FIG. 1 shows that thereis one machine and one tool (e.g., two of the three shown) that hasproductive demand 112.

FIG. 2 illustrates a graph 200 that shows a compressed air audit for afacility according to an example embodiment. The graph 200 illustrates aflow rate of compressed air over time at an example manufacturingfacility. A total capacity is shown as 740 cubic feet/minute (cfm) and amaximum plant demand is shown as 380 cfm. Thus, there is an availablecapacity of 360 cfm. The production demand is shown as 210 cfm and anaverage leak level based on non-productive load associated with leaks isshown as 170 cfm.

FIG. 2 shows each day of a number of days (e.g., nine). FIG. 2 showsnine different days of use of compressed air at the facility. As shownin FIG. 2, the demand is generally at or above a leak level. Theintelligent compressed air apparatus 101 may be used by the facility toeliminate leaks and usage outside of a production period, e.g., whenmachines/tools are in use by staff and employees at the facility. In oneexample, the production period may be a period of time each day when thefacility is staffed by employees and tools and demand sources are in useat the facility.

As an example, the intelligent compressed air apparatus 101 may be usedby the facility to save approximately $50,000 based on the followingequation: Leak rate in cubic feet/hour multiplied by an amount of timeat idle demand per week multiplied by a number of work weeks peryear=amount of compressed air saved per year. As an example, this may be170 cubic feet/minute*60 minutes/hour*((14 hours a day*five days aweek)+(forty eight hours a weekend))*52 weeks a year=62,587,200 cubicfeet per year. As an example, a standard rate may be $0.75/1000 cubicfeet. As a result, the intelligent air compression apparatus 101 maysave the facility $46,940.40 per year.

FIG. 3 illustrates a block diagram of the computing device 108 of theintelligent compressed air system 100 having an intelligent compressedair application 306 according to an example embodiment. The computingdevice 108 may be a computer having a processor 302 and memory, such asa laptop, desktop, tablet computer, mobile computing device (e.g., asmartphone), or a dedicated electronic device having a processor andmemory. The one or more processors 302 process machine/computer-readableexecutable instructions and data, and the memory storesmachine/computer-readable executable instructions and data including oneor more applications, including a component of the intelligentcompressed air application 306. The processor 302 and memory arehardware. The memory includes random access memory (RAM) andnon-transitory memory, e.g., a non-transitory computer-readable storagemedium such as one or more flash storages or hard drives. Thenon-transitory memory may include any tangible computer-readable mediumincluding, for example, magnetic and/or optical disks, flash drives, andthe like. Additionally, the memory may also include a dedicated fileserver having one or more dedicated processors, random access memory(RAM), a Redundant Array of Inexpensive/Independent Disks (RAID) harddrive configuration, and an Ethernet interface or other communicationinterface, among other components.

The computing device 108 uses the intelligent compressed air application306 to transmit data and messages and receive messages, data, and/orresources from one or more client computing devices. As an example, thedata may be sensor data associated with the one or more sensor devices104, command data associated with the one or more smart control valves102, schedule data, rule data associated with the one or more smartcontrol valves, and other information and data.

The computing device 108 includes computer readable media (CRM) 304 inmemory on which the intelligent compressed air application 306 or otheruser interface or application is stored. The computer readable media mayinclude volatile media, nonvolatile media, removable media,non-removable media, and/or another available medium that can beaccessed by the processor 302. By way of example and not limitation, thecomputer readable media comprises computer storage media andcommunication media. Computer storage media includes non-transitorystorage memory, volatile media, nonvolatile media, removable media,and/or non-removable media implemented in a method or technology forstorage of information, such as computer/machine-readable/executableinstructions, data structures, program modules, or other data.Communication media may embody computer/machine-readable/executableinstructions, data structures, program modules, or other data andinclude an information delivery media or system, both of which arehardware.

The intelligent compressed air application 306 may include a sensor datareceiver module 308 for receiving sensor data from the one or moresensor devices 104. As an example, the sensor devices 104 may sendsensor data using the communication network 106 to the sensor datareceiver module 308. The sensor data receiver module 308 may store thesensor data in the computer readable media 304 and/or in anotherlocation. The sensor data may include a current value of flow ratethrough an associated compressed air line as well as other data such astemperature data, temperature data, pressure data, and humidity data,among other data.

In one example, the sensor data receiver module 308 may use pseudocodesuch as the following example below. In the example below, the computingdevice 108 may read the sensor data, convert the sensor data to cfm, andsend the sensor data to the user interface module 314 for display.

import socket import paho.mqtt.client as mqtt import json import timefrom mcp3208 import MCP3208 adc = MCP3208( ) THINGSBOARD_HOST =‘example.compute.amazonaws.com’ ACCESS_TOKEN = ‘12345’ print(‘running’)sensor_data = {‘flow’: 0} client = mqtt.Client( ) print(‘1’)client.username_pw_set(ACCESS_TOKEN) def publish( ):client.connect(THINGSBOARD_HOST, 1883, 1)   print(i)  client.loop_start( )   time.sleep(4)   flow = adc.read(1)  sensor_data[‘flow’] = flow  client.publish(‘v1/devices/me/telemetry’,json.dumps(sensor_data),1)  print(‘published’)   client.loop_stop( ) else:   return try: print(‘started’)  while True:   publish( ) except KeyboardInterrupt: pass client.disconnect( ) client.loop_stop( ) print(‘disconnected’)

The intelligent compressed air application 306 may further include acontrol valve controller module 310 for sending one or more commands tothe one or more smart control valves 102 based on the sensor data andother information. As an example, the control valve controller module310 may compare the sensor data from the at least one sensor device 104with a threshold to determine whether there is one of productive demand112 and non-productive demand 114 from a demand source connected to thecompressed air line such as a machine or tool.

The control valve controller module 310 may send a command to the atleast one smart control valve 102 based on the one of the productivedemand 112 and the non-productive demand 114 from the demand source andoperate the at least one smart control valve 102 based on the command toopen the smart control valve 102 when there is productive demand 112 andclose the smart control valve 102 when there is non-productive demand114.

The intelligent compressed air application 306 may include a schedulingmodule 312 for receiving schedule information from a user of the system100. As an example, the schedule information may include informationassociated with the facility as a whole such as operating hours of thefacility and days of operation of the facility. In addition, theschedule information may include control valve open/close commands thatmay occur at a particular time. The schedule information may include atimed pattern of opening and closing the smart control valves at a sametime each day when the facility is in operation.

As an example, a first control valve located in a compressed air line ofthe facility may open when the facility opens each morning at 6 a.m. Thefirst control valve may remain open until the facility ceases productionat 5 p.m. each day and at that time the first control valve may close.The control valve controller module 310 may use the schedule informationto operate the at least one smart control valve 102. In addition, thecontrol valve controller module 310 may use historical information tooperate the at least one smart control valve 102, rule information tooperate the at least one smart control valve 102, and also may usemachine learning to operate the at least one smart control valve 102autonomously.

As an example, the rule information may include one or more rules suchas a rule that if a sensor device 104 detects that an associated machineor tool has no demand for a particular period of time, e.g., thirtyminutes, the associated smart control valve 102 may close. As anotherexample, if a sensor device 104 detects that an associated machine ortool has demand when the associated smart control valve 102 is closed,then the associated smart control valve 102 may open after a number ofseconds, e.g., five seconds. As another example, if a sensor device 104detects an air usage increase or decrease for a particular period oftime, then the computing device 108 may send one or more alerts to aclient computing device. The alerts may be push notifications, emails,and/or another type of automated alert that may be sent to a user of aclient computing device.

The intelligent compressed air application 306 may include a userinterface module 314. The user interface module 314 receives requests orother communications from the client computing devices and transmits arepresentation of requested information, user interface elements, andother data and communications to the client computing device fordisplay. As an example, the user interface module 314 generates a nativeand/or web-based graphical user interface (GUI) that accepts input andprovides output by generating content that is transmitted via thecommunications network 106 and viewed by a user of the client computingdevice or the computing device 108. The user interface module 314 mayprovide realtime, automatically and dynamically refreshed information tothe user of the client computing device using Java, Javascript, AJAX(Asynchronous Javascript and XML), ASP.NET, Microsoft .NET, and/ornode.js, among others. The user interface module 314 may send data toother modules of the intelligent compressed air application 306 of thecomputing device 108 and retrieve data from other modules of theintelligent compressed air application 306 of the computing deviceasynchronously without interfering with the display and behavior of theintelligent compressed air application 306 displayed by the clientcomputing device or the computing device 108. As an example, data may beretrieved using XMLHttpRequest objects or using WebSockets.

FIG. 4 illustrates a flowchart of a process 400 for operating theintelligent compressed air system 100, according to an exampleembodiment. In step 402, the computing device 108 may receive sensordata from the least one sensor device 104 in a compressed air line. Thecompressed air line may be between the supply side system 110 and ademand source and may be one compressed air line in a facility of one ormore compressed air lines. The at least one sensor device 104 may be aflow sensor and/or a pressure sensor in one of the compressed air lines.

In step 404, the computing device 108 may determine if there iscurrently productive demand 112 or non-productive demand 114 from thedemand source based on the sensor data from the least one sensor device104. The computing device 108 may compare the sensor data from the atleast one sensor device 104 with a threshold to determine whether thereis the productive demand 112 or non-productive demand 114 from thedemand source connected to the compressed air line.

In step 406, the computing device 108 may store the sensor data in thecomputer readable media 304 and/or in another location. In step 408, thecomputing device 108 may send a command to the at least one smartcontrol valve 102 based on the one of the productive demand 112 and thenon-productive demand 114 from the demand source. In addition, thecomputing device 108 may receive a schedule associated with a facilityand send the command to the at least one smart control valve 102 basedon the schedule associated with the facility. As another example, thecomputing device 108 may receive at least one conditional ruleassociated with the compressed air line and send the command to the atleast one smart control valve 102 based on the at least one conditionalrule. As another example, the computing device 108 may receivehistorical data associated with the compressed air line and send thecommand to the at least one smart control valve 102 based on thehistorical data. Over time, the computing device 108 may use machinelearning to train the smart control valve 102 using the historical dataor environmental data. The historical data or environmental data may bekey card access data for the facility, heating, ventilation, and airconditioning (HVAC) data, process parameter data, or another type ofdata.

In step 410, the computing device 108 may operate the at least one smartcontrol valve 102 based on the command to open the smart control valve102 when there is productive demand 112 and close the smart controlvalve 102 when there is non-productive demand 114. The smart controlvalve 102 may be a flow control valve such as one of a ball valve, abutterfly valve, and a solenoid valve that is connected to a motorizedsystem to operate the smart control valve.

In step 412, the computing device 108 may send a graphical userinterface representing data associated with the system 100 to a clientcomputing device for display on a display device. An example of agraphical user interface is shown in FIG. 6.

FIG. 5 illustrates a usage graph 500 associated with a plant or facilitythat is determined by the intelligent compressed air system 100according to an example embodiment. As shown in FIG. 5, there is a mainflow rate of a fluid such as compressed air through one or more lines ata facility or plant. FIG. 5 shows a line on the usage graph thatindicates a flow rate in cfm over a period of time. As an example, FIG.5 shows flow rate in the line from Jul. 5, 2019 at 20:29 to Jul. 6, 2019at 18:29:04.

FIG. 6 illustrates a graphical user interface 600 of the intelligentcompressed air application 306 according to an example embodiment. FIG.6 shows a representation of a floor layout at a facility or plant andmay indicate a current status of each smart control valve such aswhether the valve is open or closed. FIG. 6 shows that there is a valveA and a valve B on the floor of the plant. In one example, the valve Aand the valve B may be a user interface element that when selected by auser of a client computing device displays a graph associated with thevalve such as shown in FIG. 5. In addition, each of the sensor devices104 associated with the facility or plant may have a selectable userinterface element. The user may select a user interface elementassociated with each of the sensor devices 104 to view informationassociated with the sensor device such as leak information. The user ofthe client computing device may provide input to the graphical userinterface 600 using a mouse, keyboard, or touchscreen, among other inputdevices.

In addition, FIG. 6 shows an interface that allows a user to set andview a schedule associated with the intelligent compressed air system100 at the plant. FIG. 6 shows a schedule of the intelligent compressedair system 100 from Aug. 4 to Aug. 9, 2019. As shown in FIG. 6, a firstvalve is scheduled to open at 6 a.m. on Monday, August 5, Tuesday,August 6, Wednesday, August 7, Thursday, August 8, and Friday, August 9.A second valve is scheduled to open at 4:21 p.m. on Monday, August 5,Tuesday, August 6, Wednesday, August 7, Thursday, August 8, and Friday,August 9. The first valve and the second valve are scheduled to close at5:20 p.m. on Monday, August 5, Tuesday, August 6, Wednesday, August 7,Thursday, August 8, and Friday, August 9. On Saturday August 10, thesecond valve is scheduled to open at 4:21 p.m. and close at 5:20 p.m.

FIG. 6 illustrates user interface elements that allow a user to add ascheduled event and search for scheduled events. In addition, the userinterface may be displayed as a calendar view and may display a list ofevents.

FIG. 7 illustrates an example computing system 700 that may implementvarious systems, such as the smart control valve 102, the sensor device104, the computing device 108, and the methods discussed herein, such asprocess 400. A general purpose computer system 700 is capable ofexecuting a computer program product to execute a computer process. Dataand program files may be input to the computer system 700, which readsthe files and executes the programs therein. Some of the elements of ageneral purpose computer system 700 are shown in FIG. 7 wherein aprocessor 702 is shown having an input/output (I/O) section 704, acentral processing unit (CPU) 706, and a memory section 708. There maybe one or more processors 702, such that the processor 702 of thecomputing system 700 comprises a single central-processing unit 706, ora plurality of processing units, commonly referred to as a parallelprocessing environment. The computer system 700 may be a conventionalcomputer, a server, a distributed computer, or any other type ofcomputer, such as one or more external computers made available via acloud computing architecture. The presently described technology isoptionally implemented in software devices loaded in memory 708, storedon a configured DVD/CD-ROM 710 or storage unit 712, and/or communicatedvia a wired or wireless network link 714, thereby transforming thecomputer system 700 in FIG. 7 to a special purpose machine forimplementing the described operations.

The memory section 708 may be volatile media, nonvolatile media,removable media, non-removable media, and/or other media or mediums thatcan be accessed by a general purpose or special purpose computingdevice. For example, the memory section 708 may include non-transitorycomputer storage media and communication media. Non-transitory computerstorage media further may include volatile, nonvolatile, removable,and/or non-removable media implemented in a method or technology for thestorage (and retrieval) of information, such ascomputer/machine-readable/executable instructions, data and datastructures, engines, program modules, and/or other data. Communicationmedia may, for example, embody computer/machine-readable/executable,data structures, program modules, algorithms, and/or other data. Thecommunication media may also include an information delivery technology.The communication media may include wired and/or wireless connectionsand technologies and be used to transmit and/or receive wired and/orwireless communications.

The I/O section 704 is connected to one or more user-interface devices(e.g., a keyboard 716 and a display unit 718), a disc storage unit 712,and a disc drive unit 720. Generally, the disc drive unit 720 is aDVD/CD-ROM drive unit capable of reading the DVD/CD-ROM medium 710,which typically contains programs and data 722. Computer programproducts containing mechanisms to effectuate the systems and methods inaccordance with the presently described technology may reside in thememory section 704, on a disc storage unit 712, on the DVD/CD-ROM medium710 of the computer system 700, or on external storage devices madeavailable via a cloud computing architecture with such computer programproducts, including one or more database management products, web serverproducts, application server products, and/or other additional softwarecomponents. Alternatively, a disc drive unit 720 may be replaced orsupplemented by another storage medium drive unit. The network adapter724 is capable of connecting the computer system 700 to a network viathe network link 714, through which the computer system can receiveinstructions and data. Examples of such systems include personalcomputers, Intel or PowerPC-based computing systems, AMD-based computingsystems, ARM-based computing systems, and other systems running aWindows-based, a UNIX-based, or other operating system. It should beunderstood that computing systems may also embody devices such asPersonal Digital Assistants (PDAs), mobile phones, tablets or slates,multimedia consoles, gaming consoles, set top boxes, etc.

When used in a LAN-networking environment, the computer system 700 isconnected (by wired connection and/or wirelessly) to a local networkthrough the network interface or adapter 724, which is one type ofcommunications device. When used in a WAN-networking environment, thecomputer system 700 typically includes a modem, a network adapter, orany other type of communications device for establishing communicationsover the wide area network. In a networked environment, program modulesdepicted relative to the computer system 700 or portions thereof, may bestored in a remote memory storage device. It is appreciated that thenetwork connections shown are examples of communications devices for andother means of establishing a communications link between the computersmay be used.

In an example implementation, source code executed by the intelligentcompressed air system 100, a plurality of internal and externaldatabases, source databases, and/or cached data on servers are stored inmemory of the smart control valve 102, memory of the sensor device 104,memory of the computing device 108, or other storage systems, such asthe disk storage unit 712 or the DVD/CD-ROM medium 710, and/or otherexternal storage devices made available and accessible via a networkarchitecture. The source code executed by the computing system 700 maybe embodied by instructions stored on such storage systems and executedby the processor 702.

Some or all of the operations described herein may be performed by theprocessor 702, which is hardware. Further, local computing systems,remote data sources and/or services, and other associated logicrepresent firmware, hardware, and/or software configured to controloperations of the at least one smart control valve 102, the at least onesensor device 104, the at least one computing device 108, and/or othercomponents. Such services may be implemented using a general purposecomputer and specialized software (such as a server executing servicesoftware), a special purpose computing system and specialized software(such as a mobile device or network appliance executing servicesoftware), or other computing configurations. In addition, one or morefunctionalities disclosed herein may be generated by the processor 702and a user may interact with a Graphical User Interface (GUI) using oneor more user-interface devices (e.g., the keyboard 716, the display unit718, and the user devices 704) with some of the data in use directlycoming from online sources and data stores. The system set forth in FIG.7 is but one possible example of a computer system that may employ or beconfigured in accordance with aspects of the present disclosure.

In the present disclosure, the methods disclosed may be implemented assets of instructions or software readable by a device. Further, it isunderstood that the specific order or hierarchy of steps in the methodsdisclosed are instances of example approaches. Based upon designpreferences, it is understood that the specific order or hierarchy ofsteps in the method can be rearranged while remaining within thedisclosed subject matter. The accompanying method claims presentelements of the various steps in a sample order, and are not necessarilymeant to be limited to the specific order or hierarchy presented.

The described disclosure may be provided as a computer program product,or software, that may include a non-transitory machine-readable mediumhaving stored thereon executable instructions, which may be used toprogram a computer system (or other electronic devices) to perform aprocess according to the present disclosure. A non-transitorymachine-readable medium includes any mechanism for storing informationin a form (e.g., software, processing application) readable by a machine(e.g., a computer). The non-transitory machine-readable medium mayinclude, but is not limited to, magnetic storage medium, optical storagemedium (e.g., CD-ROM); magneto-optical storage medium, read only memory(ROM); random access memory (RAM); erasable programmable memory (e.g.,EPROM and EEPROM); flash memory; or other types of medium suitable forstoring electronic executable instructions.

The description above includes example systems, methods, techniques,instruction sequences, and/or computer program products that embodytechniques of the present disclosure. However, it is understood that thedescribed disclosure may be practiced without these specific details.

It is believed that the present disclosure and many of its attendantadvantages will be understood by the foregoing description, and it willbe apparent that various changes may be made in the form, constructionand arrangement of the components without departing from the disclosedsubject matter or without sacrificing all of its material advantages.The form described is merely explanatory, and it is the intention of thefollowing claims to encompass and include such changes.

While the present disclosure has been described with reference tovarious embodiments, it will be understood that these embodiments areillustrative and that the scope of the disclosure is not limited tothem. Many variations, modifications, additions, and improvements arepossible. More generally, embodiments in accordance with the presentdisclosure have been described in the context of particularimplementations. Functionality may be separated or combined in blocksdifferently in various embodiments of the disclosure or described withdifferent terminology. These and other variations, modifications,additions, and improvements may fall within the scope of the disclosureas defined in the claims that follow.

What is claimed is:
 1. A system comprising: at least one sensor devicein a compressed air line; at least one smart control valve in thecompressed air line; and at least one processor to: receive sensor dataassociated with the compressed air line from the at least one sensordevice; store the sensor data in a computer-readable storage medium;compare the sensor data from the at least one sensor device with athreshold to determine whether there is one of productive demand andnon-productive demand from a demand source connected to the compressedair line; send a command to the at least one smart control valve basedon the one of the productive demand and the non-productive demand fromthe demand source; and operate the at least one smart control valvebased on the command to open the smart control valve when there isproductive demand and close the smart control valve when there isnon-productive demand.
 2. The system of claim 1, wherein the at leastone sensor device comprises one of a flow sensor and a pressure sensorin the compressed air line.
 3. The system of claim 1, wherein the smartcontrol valve comprises a flow control valve that is connected to amotorized system to operate the smart control valve.
 4. The system ofclaim 1, the at least one processor further to receive a scheduleassociated with a facility and send the command to the at least onesmart control valve based on the schedule associated with the facility.5. The system of claim 1, the at least one processor further to receiveat least one conditional rule associated with the compressed air lineand send the command to the at least one smart control valve based onthe at least one conditional rule.
 6. The system of claim 1, the atleast one processor further to receive historical data associated withthe compressed air line and send the command to the at least one smartcontrol valve based on the historical data.
 7. The system of claim 1,the at least one processor to send a graphical user interface thatrepresents the sensor data associated with the compressed air line to aclient computing device.
 8. A method comprising: receiving, by at leastone processor, sensor data associated with a compressed air line from atleast one sensor device; storing, by the at least one processor, thesensor data in a computer-readable storage medium; comparing, by the atleast one processor, the sensor data from the at least one sensor devicewith a threshold to determine whether there is one of productive demandand non-productive demand from a demand source connected to thecompressed air line; sending, by the at least one processor, a commandto at least one smart control valve in the compressed air line based onthe one of the productive demand and the non-productive demand from thedemand source; and operating, by the at least one processor, the atleast one smart control valve based on the command to open the smartcontrol valve when there is productive demand and close the smartcontrol valve when there is non-productive demand.
 9. The method ofclaim 8, wherein the at least one sensor device comprises one of a flowsensor and a pressure sensor in the compressed air line.
 10. The methodof claim 8, wherein the smart control valve comprises a flow controlvalve that is connected to a motorized system to operate the smartcontrol valve.
 11. The method of claim 8, further comprising receiving aschedule associated with a facility and sending the command to the atleast one smart control valve based on the schedule associated with thefacility.
 12. The method of claim 8, further comprising receiving atleast one conditional rule associated with the compressed air line andsending the command to the at least one smart control valve based on theat least one conditional rule.
 13. The method of claim 8, furthercomprising receiving historical data associated with the compressed airline and sending the command to the at least one smart control valvebased on the historical data.
 14. The method of claim 8, furthercomprising sending a graphical user interface that represents the sensordata associated with the compressed air line to a client computingdevice.
 15. A non-transitory computer-readable storage medium, havinginstructions stored thereon that, when executed by a computing devicecause the computing device to perform operations, the operationscomprising: receiving sensor data associated with a compressed air linefrom at least one sensor device; storing the sensor data in thenon-transitory computer-readable storage medium; comparing the sensordata from the at least one sensor device with a threshold to determinewhether there is one of productive demand and non-productive demand froma demand source connected to the compressed air line; sending a commandto at least one smart control valve in the compressed air line based onthe one of the productive demand and the non-productive demand from thedemand source; and operating the at least one smart control valve basedon the command to open the smart control valve when there is productivedemand and close the smart control valve when there is non-productivedemand.
 16. The non-transitory computer-readable storage medium of claim15, wherein the at least one sensor device comprises one of a flowsensor and a pressure sensor in the compressed air line.
 17. Thenon-transitory computer-readable storage medium of claim 15, wherein thesmart control valve comprises a flow control valve that is connected toa motorized system to operate the smart control valve.
 18. Thenon-transitory computer-readable storage medium of claim 15, theoperations further comprising receiving a schedule associated with afacility and sending the command to the at least one smart control valvebased on the schedule associated with the facility.
 19. Thenon-transitory computer-readable storage medium of claim 15, theoperations further comprising receiving at least one conditional ruleassociated with the compressed air line and sending the command to theat least one smart control valve based on the at least one conditionalrule.
 20. The non-transitory computer-readable storage medium of claim15, the operations further comprising receiving historical dataassociated with the compressed air line and sending the command to theat least one smart control valve based on the historical data.
 21. Thenon-transitory computer-readable storage medium of claim 15, theoperations further comprising sending a graphical user interface thatrepresents the sensor data associated with the compressed air line to aclient computing device.